Method for constructing structure

Abstract

To provide a construction method of a structure capable of manufacturing a highly artistic structure using an additive manufacturing device.SOLUTION: A method for constructing a structure includes a structure construction step of discharging a hydraulic mixture (31) from an additive manufacturing unit (10) of an additive manufacturing device (1) to construct a structure (3), and a finish machining step of forming irregularities on a 3f of the structure (3) by a finish machining unit (20) before the hydraulic mixture (3) sets. The finish machining unit (20) includes a first machining unit (24) configured to form first type irregularities on the 3f of the structure (3).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for constructing a structure. [Background technology]

[0002] BACKGROUND ART Highly artistic exterior finishes that create three-dimensional unevenness on the surfaces of walls and pillars have been known for some time.

[0003] Meanwhile, in recent years, a method has been proposed in which a concrete member made of cement-based material is extruded to a predetermined location using an additive manufacturing device or the like to construct a structure (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 4527107 Summary of the Invention [Problem to be solved by the invention]

[0005] Although conventional additive manufacturing devices can stack concrete components, they have the problem of not being able to process the surface into the desired shape to produce highly artistic structures.

[0006] Therefore, the present invention has been made in consideration of the above circumstances, and provides a method for constructing a structure that can produce a highly artistic structure using an additive manufacturing device. [Means for solving the problem]

[0007] In order to achieve the above object, the present invention employs the following means. That is, the method for constructing a structure according to the present invention comprises a structure construction step in which a hydraulic mixture is discharged from an additive manufacturing unit of an additive manufacturing device to construct a structure, and a finishing processing step in which, using a finishing processing unit, processing is performed to form irregularities on the surface of the structure before the hydraulic mixture solidifies.

[0008] In the method for constructing a structure configured as described above, a hydraulic mixture is discharged from the additive manufacturing unit of an additive manufacturing device to construct a structure. Before the hydraulic mixture sets, the finishing unit processes the structure to form irregularities on its surface. By forming irregularities on the surface of the structure to create a three-dimensional decorative finish, it is possible to construct a complex, intricate, and highly artistic structure that cannot be achieved by simply layering or spraying the hydraulic mixture. Note that the term "hydraulic mixture" refers to a material that includes various cementitious materials (e.g., cement paste, mortar, concrete, etc.) and geopolymer compositions.

[0009] In addition, in the method for constructing a structure according to the present invention, the finishing processing unit may have a first processing unit that processes the surface of the structure to form a first type of unevenness, and a second processing unit that processes the surface of the structure to form a second type of unevenness that is different from the first type.

[0010] In the method for constructing a structure configured in this manner, a first type of unevenness is formed on the surface of the structure by the first processing unit, and a second type of unevenness different from the first type is formed on the surface of the structure by the second processing unit. Thus, the surface of the structure is subjected to both the first type of processing and the second type of processing, making it possible to construct a structure with even greater artistic quality.

[0011] In addition, in the method for constructing a structure according to the present invention, the finishing processing unit may be connected to the additive manufacturing unit.

[0012] In the method for constructing a structure configured in this manner, the finishing unit is connected to the additive manufacturing unit, and therefore the finishing unit and the additive manufacturing unit can be operated in conjunction with each other.

[0013] In addition, in the method for constructing a structure according to the present invention, the finishing processing unit may be provided separately from the additive manufacturing unit.

[0014] In the method for constructing a structure configured in this manner, the finishing unit is provided separately from the additive manufacturing unit. Therefore, by separating the device equipped with the finishing unit from the additive manufacturing device equipped with the additive manufacturing unit, each device can be made smaller. [Effects of the Invention]

[0015] According to the method for constructing a structure of the present invention, highly artistic structures can be manufactured using an additive manufacturing device. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a front view showing a method for constructing a structure according to a first embodiment of the present invention. FIG. [Figure 2] 1 is a perspective view showing a method for constructing a structure according to a first embodiment of the present invention. FIG. [Figure 3] FIG. 10 is a front view showing a method for constructing a structure according to a second embodiment of the present invention. [Figure 4] FIG. 10 is a perspective view showing a method for constructing a structure according to a second embodiment of the present invention. [Figure 5] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 6] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 7] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 8] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 9] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 10] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 11] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 12] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 13] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 14] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 15] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 16] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 17] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 18] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 19] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 20] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 21] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 22] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 23] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 24] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 25] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 26] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 27]1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 28] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 29] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 30] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 31] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 32] 1 is an example of a surface finish according to a method for constructing a structure according to an embodiment of the present invention. [Figure 33] FIG. 10 is a diagram showing an example of using a part of a method for constructing a structure according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] (First embodiment) A method for constructing a structure according to a first embodiment of the present invention will be described with reference to the drawings. In this embodiment, a case where unevenness is formed on the surface of a concrete structure such as a wall or a pillar will be described. The method for constructing a structure includes a structure construction step and a finishing step.

[0018] 1, an additive manufacturing apparatus 1 is used. The additive manufacturing apparatus 1 has an additive manufacturing unit 10 and a finishing unit 20.

[0019] The additive manufacturing unit 10 has a nozzle 11, a lifter unit 12, a self-propelled unit 13, and a hose 14. The lifter unit 12 supports the nozzle 11 and the hose 14 that supplies unhardened (unset) concrete fluid (hydraulic mixture) 31 to the nozzle 11, and raises and lowers the nozzle 11 to a predetermined height. The self-propelled unit 13 is connected to the lifter unit 12. The self-propelled unit 13 propels itself to a predetermined location and moves the nozzle 11 in conjunction with the lifter unit 12. The concrete fluid 31 is ejected from the nozzle 11. The concrete fluid 31 is ejected from the nozzle 11 in a pushed-out manner. The configuration of the additive manufacturing unit 10 is not particularly limited. The additive manufacturing unit 10 may be remotely controlled.

[0020] An example of a hydraulic mixture is a concrete fluid 31, which is a material including various cementitious materials (e.g., cement paste, mortar, concrete, etc.), a geopolymer composition, etc. The hydraulic mixture may also be plaster.

[0021] The finishing section 20 has a first processing means 21 and a second processing means 26 .

[0022] As shown in FIG. 2, the first processing means 21 has a first connection portion 22, a first arm portion 23, and a first processing portion 24. The first connection portion 22 is connected to the lifter portion 12. Note that the first connection portion 22 may be connected to a part of the additive manufacturing unit 10 other than the lifter portion 12. The first arm portion 23 extends from the first connection portion 22. The first arm portion 23 has multiple first arm members 23a connected to each other so as to be freely deformed via first joint portions 23b. The first processing portion 24 is provided at the tip of the first arm portion 23. The first processing portion 24 is a brush or guide plate capable of smoothing (processing to form a first type of unevenness) the surface 3f of the concrete fluid 31 (structure 3) and performs rough processing on the surface 3f.

[0023] The second processing means 26 has a second connection portion 27, a second arm portion 28, and a second processing portion 29. The second connection portion 27 is connected to the lifter portion 12. Note that the second connection portion 27 may be connected to a part of the additive manufacturing unit 10 other than the lifter portion 12. The second arm portion 28 extends from the second connection portion 27. The second arm portion 28 has multiple second arm members 28a connected to each other so as to be freely deformable via second joint portions 28b. The second processing portion 29 is provided at the tip of the second arm portion 28. The second processing portion 29 is a spatula capable of scraping or piling the concrete fluid 31 from the surface 3f of the concrete fluid 31 (structure 3) (processing to form a second type of unevenness), and performs fine processing on the surface 3f.

[0024] The first processing means 21 and the second processing means 26 can move in conjunction with the lifter unit 12 of the additive manufacturing unit 10. The finishing processing unit 20 is equipped with a learning unit (not shown) and is capable of learning using AI (artificial intelligence), and may be capable of producing a highly artistic three-dimensional decorative finish.

[0025] In the structure construction process, a structure 3 of a predetermined shape is constructed by discharging a concrete fluid 31 from the nozzle 11 of the additive manufacturing unit 10 and layering it from bottom to top. Note that the concrete fluid 31 may be discharged from the nozzle 11 in a sprayed (ejected) manner to construct a structure 3 of a predetermined shape. The object to be sprayed may be a horizontal surface, a vertical surface, or a surface with an inclination.

[0026] In the finishing process, the first processing unit 24 and the second processing unit 29 of the finishing unit 20 process the surface 3f of the structure 3 to form irregularities before the concrete fluid 31 sets. First, the first processing means 21 accesses the surface 3f of the structure 3, and the first processing unit 24 smooths the surface 3f to a rough shape to form an intermediate finished surface 3a. The second processing means 26 accesses the intermediate finished surface 3a smoothed by the first processing unit 24, and the second processing unit 29 scrapes or builds up the concrete fluid 31 from the intermediate finished surface 3a to form a final finished surface 3b. Note that the first processing unit 24 may form the intermediate finished surface 3a on part of the surface 3f by smoothing the surface 3f, and the second processing unit 29 may form the final finished surface 3b on the other part of the surface 3f by scraping or building up the concrete fluid 31 from the surface 3f, so that ultimately, the intermediate finished surface 3a and the final finished surface 3b coexist on the surface 3f of the structure 3. In addition, before the concrete fluid 31 sets, it means that the penetration resistance value measured by the penetration resistance test device in the JISA1147:2019 concrete setting time test method is 8N / mm 2 The situation is as follows:

[0027] In the method for constructing a structure configured in this manner, a concrete fluid 31 is discharged from the additive manufacturing unit 10 of the additive manufacturing device 1 to construct a structure 3. Before the concrete fluid 31 sets, the finishing unit 20 processes the surface 3f of the structure 3 to form irregularities. Thus, by forming irregularities on the surface 3f of the structure 3 to create a three-dimensional decorative finish, it is possible to construct a complex, intricate, and highly artistic structure 3 that cannot be constructed by simply layering or spraying the concrete fluid 31.

[0028] Furthermore, the first processing unit 24 smooths the surface 3f of the structure 3 to form an intermediate finished surface 3a. The second processing unit 29 scrapes and piles up the concrete fluid 31 from the surface 3f of the structure 3 to form a final finished surface 3b. Thus, the surface 3f of the structure 3 is smoothed and scraped and piled up with the concrete fluid 31, so that a structure 3 with even higher artistic quality can be constructed.

[0029] Furthermore, the finishing processing unit 20 is connected to the additive manufacturing unit 10. Therefore, the finishing processing unit 20 and the additive manufacturing unit 10 can be operated in conjunction with each other.

[0030] Furthermore, since the three-dimensional decorative finish on the surface 3f of the structure 3 is constructed from materials that are integrated with the structure 3, there is no risk of it peeling off like a relief panel that is installed later on the surface 3f of the structure 3, and it is highly durable and weather-resistant.

[0031] Furthermore, even on the large surface 3f of the structure 3, the finished surface can be produced seamlessly, which is excellent in artistic quality.

[0032] Second Embodiment Next, a method for constructing a structure according to a second embodiment of the present invention will be described mainly with reference to Figures 3 and 4. In the embodiment described below, parts having substantially the same configuration as those in the first embodiment will be given the same reference numerals and detailed description thereof will be omitted.

[0033] As shown in Fig. 3, this embodiment uses an additive manufacturing system 1A. The additive manufacturing system 1A has an additive manufacturing apparatus 10A and a finishing processing apparatus 20A. In this embodiment, the additive manufacturing apparatus 10A and the finishing processing apparatus 20A are not connected to each other, but are provided separately (independently).

[0034] The additive manufacturing apparatus 10A has an additive manufacturing unit 10. That is, the additive manufacturing apparatus 10A has a nozzle 11, a lifter unit 12, a self-propelled unit 13, and a hose 14.

[0035] The finishing device 20A has a lifter unit 41, a self-propelled unit 42, and a finishing unit 20. That is, the finishing device 20A has the lifter unit 41, the self-propelled unit 42, the first processing means 21, and the second processing means 26.

[0036] The self-propelled unit 42 is capable of self-propelling within a predetermined location. The lifter unit 41 is connected to the self-propelled unit 42. As shown in FIG. 4, the first processing means 21 and the second processing means 26 are provided at the tip of the lifter unit 41 of the additive manufacturing apparatus 10A. The lifter unit 41 moves the first processing unit 24 of the first processing means 21 and the second processing unit 29 of the second processing means 26. The finishing processing apparatus 20A may be remotely operable.

[0037] In the method for constructing a structure configured in this manner, a concrete fluid 31 is discharged from the additive manufacturing unit 10 of the additive manufacturing device 10A to construct a structure 3. Before the concrete fluid 31 sets, the finishing unit 20 processes the surface 3f of the structure 3 to form irregularities. Thus, by forming irregularities on the surface 3f of the structure 3 to create a three-dimensional decorative finish, it is possible to construct a complex, intricate, and highly artistic structure 3 that cannot be constructed by simply layering or spraying the concrete fluid 31.

[0038] Furthermore, the finishing unit 20 is provided separately from the additive manufacturing unit 10. Therefore, by separating the finishing processing device 20A equipped with the finishing processing unit 20 from the additive manufacturing device 10A equipped with the additive manufacturing unit 10, it is possible to make the finishing processing device 20A and the additive manufacturing device 10A each smaller. In particular, since the finishing processing device 20A does not supply concrete fluid 31 and is configured only to have lightweight tools such as brushes and spatulas, it is also possible to employ a small and lightweight industrial robot.

[0039] The assembly procedures, shapes and combinations of the components, etc. shown in the above-described embodiments are merely examples, and various modifications can be made based on design requirements, etc., within the scope of the present invention.

[0040] For example, the first processing unit 24 and the second processing unit 29 may be any device other than a brush or spatula that can process the surface 3f of the concrete fluid 31 to form irregularities. For example, the first processing unit 24 and the second processing unit 29 may be configured to smooth the surface 3f of the concrete fluid 31 with a trowel, and then process the surface 3f of the concrete fluid 31 to form irregularities with the second processing unit.

[0041] Furthermore, in the embodiment described above, the finishing processing unit 20 is equipped with two types of processing units, the first processing unit 24 and the second processing unit 29, but it may also be equipped with three or more types of processing means. The greater the number of processing units, the more processing work that can be performed in parallel to form irregularities, improving workability. It is also possible to perform processing work on multiple surfaces, such as the front surface 3f and back surface (the surface opposite to the front surface 3f) of the structure 3. Alternatively, all processing work may be performed by a single processing unit with a spatula. An additional hydraulic mixture may be sprayed onto the surface 3f of the structure 3 formed by the additive manufacturing apparatus 1 to form more three-dimensional irregularities.

[0042] Furthermore, a coating may be applied to protect the surface 3f of the structure 3 and prevent deterioration. Coatings that enhance durability, weather resistance, and antifouling properties, such as photocatalysts, may also be used in combination. Furthermore, the surface 3f of the structure 3 may be colored, or a colored concrete fluid colored by mixing pigments may be used.

[0043] It is also possible to use a small robot to embed lighting fixtures such as LED lamps in predetermined locations before the concrete fluid 31 sets. For example, it is also possible to incorporate lighting fixtures into eyes drawn in three-dimensional decorations to make them glow.

[0044] It is also possible to combine it with stereolithography or a metal 3D printer to insert a shaped object into the concrete fluid 31 before it hardens, integrating different types of finishing materials. This also makes it possible to create glossy parts.

[0045] Furthermore, when combined with a 3D scanner, it becomes possible to replicate and restore any shape in three dimensions.

[0046] 33, a surface material installation step of installing tiles 4 on the surface 3f of the structure 3 may be carried out in parallel with the finishing process. That is, unevenness is formed on part of the surface 3f of the structure 3, and tiles 4 are installed on other parts of the surface 3f of the structure 3. Note that in addition to tiles 4, solar panels, lighting panels, etc. may also be installed on the surface 3f of the structure 3.

[0047] In the surface material installation process, a mechanical device such as a robot arm 51 is used to attach the finishing surface 4f of the tile 4 to a vacuum suction pad 52 attached to the tip of the robot arm 51. The tile 4 is pressed against the surface 3f of the structure 3. The installation surface 4b of the tile 4, which is installed on the surface 3f of the structure 3, has a recess 4a recessed in the thickness direction of the tile 4. The recess 4a gives the installation surface 4b of the tile 4 an uneven shape. Unhardened concrete fluid 31 enters the recess 4a of the tile 4, integrating the tile 4 and the structure 3. This allows the tile 4 to be installed on the surface 3f of the structure 3, which is made of concrete fluid 31 discharged from the additive manufacturing device 1, before the concrete fluid 31 sets. Therefore, materials such as adhesives for adhering the tile 4 are not required, and the tile 4 is installed on the structure 3 before the concrete fluid 31 sets, resulting in early completion and improved workability. Furthermore, the integrity of the structure 3 and the tiles 4 is improved, and the tiles 4 are prevented from falling off. [Explanation of symbols]

[0048] 1...Additive manufacturing equipment 1A...Additive manufacturing system 3...Structure 3a...Intermediate finishing surface 3b...Final finish surface 3f…Surface 10. Additive Manufacturing Department 10A...Additive manufacturing equipment 20...Finishing section 20A...Finishing equipment 21 First processing means 24…First Processing Department 26…Second processing method 29…Second Processing Department 31…Hydraulic mixture

Claims

1. a structure construction process in which a hydraulic mixture is discharged from an additive manufacturing unit of an additive manufacturing device to construct a structure; a finishing process in which a finishing unit processes the surface of the structure to form irregularities before the hydraulic mixture sets, The finishing processing section includes: a first processing unit that processes the surface of the structure to form a first type of unevenness; A method for constructing a structure in which the first processing unit is provided at the tip of an arm unit in which arm members are freely deformed via joints.

2. The finishing processing section includes: The method for constructing a structure according to claim 1, further comprising a second processing unit for processing the surface of the structure to form a second type of unevenness different from the first type.

3. The method for constructing a structure according to claim 1 or 2, wherein the finishing unit is connected to the additive manufacturing unit.

4. The method for constructing a structure according to claim 1 or 2, wherein the finishing processing unit is provided separately from the additive manufacturing unit.

5. The method for constructing a structure according to any one of claims 1 to 4, further comprising a surface material installation step of installing tiles on the surface of the structure in parallel with the finishing step.

6. forming the first type of unevenness on a part of the surface of the structure by the first processing unit; The method for constructing a structure according to claim 5, wherein the tiles are installed on other portions of the surface of the structure.

7. 7. The method for constructing a structure according to claim 5, wherein in the surface material installation step, the tiles are adsorbed onto a vacuum suction pad provided on a robot arm and pressed onto the surface of the structure.

8. The installation surface of the tile that is installed on the surface of the structure has an uneven shape formed by forming a recess that is recessed in the plate thickness direction of the tile, 8. The method for constructing a structure according to claim 5, wherein in the surface material installation step, the tile is pressed against the surface of the structure, causing the unhardened hydraulic mixture to fill the recesses, thereby integrating the tile and the structure.

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